I really needed something to help keep my ears from hurting after wearing a face mask for a while, especially when traveling. These hat-mounted ear savers are similar to the trick of sewing buttons onto your hat, but the extra width helps keep pressure off of your entire ear. They're also more discreet.
Parts Needed:
- 2x main pieces (thicker pieces--included in the print file)
- 2x backing plates (thinner pieces--included in the print file)
- 6x 8mm M2 flat head screws. I get mine from McMaster-Carr.
Assembly Steps:
- Print the part. No supports are required.
- If necessary, use a 1/16" or 1.6mm drill bit to ensure the holes are the correct size. You may also want to use an M2 tap to start the threads, but this may not be needed.
- Mark your screw holes. On a standard 6-panel baseball cap, the center screw should go directly through the seam that is above your ear. Make sure the two screw holes that are closer to one another are facing the front.
- I find it's easiest to place one of the backing plates inside the hat and mark the holes from there, as you'll be able to situate it as far down as possible.
- Cut your screw holes. I used a sharp awl to poke small holes where my screws would go. You don't need to make these very large--just enough to get the tip of the screw through and screw it in the rest of the way.
- Insert one of the screws through the backing plate and the corresponding hole in the fabric. The backing plate has countersinks on one side that should match up with the screw head.
- Screw the first screw partially into the main piece. Don't tighten it all the way yet.
- Screw the other two screws through the backing plate and fabric and into the main piece.
- Tighten the screws. Note that since we are screwing into plastic, they may not fully feel tight--just screw them in until there is no gap between the plastic and fabric.
- Repeat steps 3-8 for the other side.
- Wear your new accessory and be safe!
alexberkowitz
